Reusable baby diaper having reusable absorbent insert

ABSTRACT

An adjustable, form fitted, reusable diaper for infants that includes a reusable or disposable pad insertable between a soft permeable inner panel and an impermeable outer panel laminated with either a soft pile or a waterproof breathable or non-breathable elastomeric non-woven material. The diaper, having an hourglass configuration when open, is provided with expandable leg openings and waistband and fitted with hidden snap closures uniquely arranged to provide waist adjustment independently of leg opening adjustment and vise-versa. The diaper&#39;s use of a high pile, permeable inner panel such as polar fleece wicks moisture quickly away from the infants body where it is absorbed by the washable, reusable pad located between the inner and outer panels. The pad is then easily removed and replaced with a clean and dry pad, often without removal of the diaper from the infant.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates generally to baby diapers and moreparticularly to the so-called reusable all-in-one diaper having multiplefabric layers with removable and washable cloth insert.

[0003] 2. General Background

[0004] Parents now have the option of using a variety of diapers fortheir child, ranging from the conventional cloth diaper washed at homeor provided by a laundry service, disposable diapers, or a combinationof these types in an all-in-one diaper. Arguments are made on all sidesregarding the health and sanitation issues, the energy and environmentalcost, as well as the economics involved in using each type. However,case studies have clearly indicated that it all comes down to a personalchoice based on the life style and economic advantages of the parent.

[0005] In cases where cloth diapering is the option of choice, frequentdiaper changes are required to keep the child dry and thereby helpreduce infections such as diaper rash. Cloth diapers absorb moisture butdo not necessarily wick moisture away from the body. Cloth diapersbecome saturated very quickly; therefore, outer waterproof covers areoften used to contain further spreading of the moisture. Such covers maysimply be made of a disposable plastic or more elaborate laminates, suchas knit polyester or cotton bonded to a urethane inner liner.Alternatively the so-called all-in-one diaper may be used that combinesthe diaper with a protective waterproof outer cover. Use of such coversor combinations often conceal the fact that the diaper is wet, as isalso the case of disposable diapers. In addition such diapers may alsoinclude absorbent disposable liners made of multiple layers of cotton orreusable insert pads that are either sewn in place or allowed to floatfree between inner and outer liner laminates,

[0006] A secondary issue focuses on the comfort of the baby with respectto the diaper applied. It is essential that the diaper be snug to insureretention and prevent leakage but not so tight as to be uncomfortable orhamper blood circulation in the child's legs due to elastic leg openingsand not so tight as to create high humidity within the diaper.

[0007] Some studies even suggest the use of two diapers per changing tohelp insure dryness. Therefore, elastic covers or diapers with hook andloop fasteners that can cut and abrade the child and the addition ofdisposable multi-layers of absorbent material is clearly not the answer.

[0008] Further, hook and loop fasteners generally only allow for waistadjustment and do nothing for the leg openings. Therefore, elastic isoften used around the leg openings. This arrangement assumes that thewaist and leg size are relative which is certainly not the case.

[0009] Obviously the key issues are to insure that the baby stays as dryas possible for as long as possible with the least bulk possible. Thebaby's comfort should be paramount and not dependent on convenience forthe diaper changer.

SUMMARY OF THE INVENTION

[0010] According to the instant invention, there is provided anadjustable, form fitted, reusable diaper for infants that includes areusable or disposable pad insertable between a soft permeable innerpanel and an impermeable outer panel laminated with either a soft pileor a waterproof breathable or non-breathable elastomeric non-wovenmaterial. The diaper, having an hourglass configuration when open, isprovided with expandable leg openings and waistband and fitted withhidden snap closures uniquely arranged to provide waist adjustmentindependently of leg opening adjustment and vise-versa. The diaper's useof a high pile permeable inner panel, such as polar fleece, wicksmoisture away from the infant's body quickly where the washable,reusable pad located between the inner and outer panels absorbs it. Thepad is then easily removed and replaced with a clean and dry pad, oftenwithout removal of the diaper from the infant.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a further understanding of the nature and objects of thepresent invention, reference should be made to the following detaileddescription taken in conjunction with the accompanying drawings, inwhich, like parts are given like reference numerals, and wherein:

[0012]FIG. 1 is an inside view of the preferred diaper embodiment;

[0013]FIG. 2 is and outside view of the preferred diaper embodiment;

[0014]FIG. 3 is an exploded view of the preferred diaper embodiment withinsert;

[0015]FIG. 4 is a peeled back view of the diaper layers; and

[0016]FIG. 5 is a partial cross section view taken along sight lines 5-5in FIG. 1;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0017] The instant infant diaper invention 10, illustrated in FIG. 1 asviewed from the inside, is contoured in the classic hour glass shapehaving elongated wings 12 along the upper portion 14 which over lap thelower portion 16 when the diaper is folded in half, thereby formingwaist closure and leg openings. The leg openings are lined with elasticsewn into the panel hem 18 to insure a snug fit around an infant's legswhen folded. A pair of male plastic snaps 20, located vertically, areprovided at each of the wing portions 12. Looking now at the outside ofthe diaper 10 as illustrated in FIG. 2, we see a dozen female plasticsnap members 22 spaced and located in a cooperative manner with the malesnaps 20, but in a unique manner. The male snap portions 20 penetrateboth the inner panel 24 and the outer liner 26, whereas the femaleportion of the snap 22 only penetrates the outer panel 26. The femalesnap portions 22 are arranged so that each of 3 pairs of snaps arelocated at an acute angle of approximately 30 degrees off each side ofthe center longitudinal axis of the diaper 10. This unique snaparrangement allows the male snaps 20 to engage the female snaps 22 inany combination; for example, the uppermost male snaps 20 can engageeither of the female snaps 22 a, 22 b or 22 c, thereby adjusting thewaist size of the diaper while the lower male snaps 20 may engage 22 d,22 e, or 22 f, thereby adjusting the leg openings. Other snaparrangements may also used to achieve the same result of allowing thewaist to be adjusted without affecting the leg opening and vice versa.All such arrangements are considered as being within the scope of theinvention.

[0018] Looking now at FIG. 4, we see the diaper 10 is a laminatecomposed of the inner panel 24 and the outer liner 26 sewn togetherperipherally, each panel being cut in a basic hour glass shape havingupper and lower body portions 14,16 connected by a narrowing orrestrictive intermediate or crotch portion 28. The upper body portion 14is elongated or elliptically shaped to form wings 12 that define a mantaray configuration. The leading edge 32 of both the inner and outerpanels are purposely not attached to each other in order to provide anaperture or mouth or opening into the space between the inner and outerpanels 24,26.

[0019] Hems 18 are provided for attaching elastic along the leg openingseither side of the crotch portion 28 seen in FIG. 3. A hem 30 is alsoprovided along the upper edge of the outer panel 26 to allow forwaistline expansion and ease of insertion of the absorbent pad. Aportion 32 of the upper edge of the inner panel 24, corresponding to thehem 30 along the upper edge of the outer panel 26, is purposely not sewnto the outer panel 26 to allow access to the space 36 seen in FIG. 5between the inner and outer panels 24,26. An absorbent pad 34 as seen inFIG. 3 may be readily inserted between the inner and outer panels 24,26and held firmly in the crotch area 28 by an infant's legs when wearingthe diaper 10. The insert 34 may be a disposable pad or any absorbent,reusable material, such as one or more folded cotton cloth diapers.

[0020] The material used for the inner and outer panels 24,26 may be aspongy, high pile polyester knit material commonly referred to as Polarfleece. The non-absorbency of the synthetic fleece material rapidlywicks wetness away from the infant where it is absorbed by the insert34. The fleece material's inability to retain moisture provides a drybarrier between the infant and the absorbent insert 34. The fleecematerial may be sprayed with a durable, water resistant chemical to helpinsure faster drying. Other previous water resistant materials areanticipated, such as velour, sheep's wool fleece, and the like.

[0021] The outer panel 26 may be a leak-proof, expandable, polyurethanelaminate 38 composed of breathable or non-breathable bonded polyesterknit material coated with DRW, known in the art as durable waterresistant chemical. Alternatively, the outer panel 26 may be a laminatecomposed of polar fleece 26 internally lined with the leak-proof,polyurethane laminate 38 composed of breathable or non-breathable bondedpolyester knit material coated with DRW or a durable water resistantchemical.

[0022] Because many varying and different embodiments may be made withinthe scope of the inventive concept herein taught, and because manymodifications may be made in the embodiments herein detailed inaccordance with the descriptive requirement of the law, it is to beunderstood that the details herein are to be interpreted as illustrativeand not in any limiting sense.

What is claimed is:
 1. A reusable infant diaper comprising: a) inner andouter panels, each panel having upper and lower elliptical portionsconnected by an narrowing incurvate intermediate portion, said upperelliptical portions having a leading edge, each of said panels attachedperipherally one to the other in matched contour; b) a first elasticstrip attached to said inner and outer panels along each side of saidintermediate portion; c) a second elastic strip attached along at leasta portion of said leading edge of said outer panel; d) a first pluralityof snap members attached to each end of both the inner and outer upperelliptical body portions; e) a second plurality of snap members attachedto said lower body portion of said outer panel cooperatively fastenablewith said first plurality of snap members; and f) a removable, reusable,absorbent pad inserted between said inner and outer panels and locatedalong said intermediate portion.
 2. The reusable infant diaper accordingto claim 1 wherein said inner and outer panels utilize a previousmaterial.
 3. The reusable infant diaper according to claim 1 wherein aninner face of said outer panel is lined with an impervious material. 4.The reusable infant diaper according to claim 1 wherein said inner andouter panels are polar fleece.
 5. The reusable infant diaper accordingto claim 1 wherein said outer panel is an expandable polyurethanelaminate coated with a durable water resistant chemical.
 6. The reusableinfant diaper according to claim 1 wherein said plurality of female snapmembers are attached to said lower body portion of said outer panel in amanner whereby said female snap members are arranged in pairs located atacute angles either side of a longitudinal center line running throughsaid upper and lower body portions.
 7. A reusable infant diapercomprising: a) inner and outer panels having an hour-glass shapecomprised of an upper body portion, a lower body portion and a narrowingincurvate intermediate portion connecting said upper and lower bodyportions, said upper and lower body portions being transverselyelliptical with said upper body portion being larger than said lowerbody portion and having a leading edge, each said panel attachedperipherally one to the other in matched contour; b) a first elasticstrip attached to said inner and outer cloth panels along each side ofsaid intermediate portion; c) a second elastic strip attached along atleast a portion of said leading edge of said outer cloth panel; d) afirst and second male snap members attached to each end of said upperbody portion; e) a plurality of female snap member cooperativelyfastenable with said first and second male snap members attached to saidlower body portion of said outer panel in a manner whereby said femalesnap members are arranged in pairs located at acute angles either sideof a longitudinal center line running through said upper and lower bodyportions; f) A reusable absorbent pad inserted between said inner andouter panels and located at least along said intermediate portion. 8.The reusable infant diaper according to claim 7 wherein said inner andouter panels utilize a previous material.
 9. The reusable infant diaperaccording to claim 7 wherein an inner face of said outer panel is linedwith an impervious material.
 10. The reusable infant diaper according toclaim 7 wherein said inner and outer panels are polar fleece.
 11. Thereusable infant diaper according to claim 7 wherein said outer panel isan expandable polyurethane laminate coated with a durable waterresistant chemical.
 12. A method for improving comfort and fit in areusable diaper comprising the steps of: a) providing a reusable diapercomprising: i) inner and outer previous fleece panels, said outer panelhaving an inner face lined with an impervious material, each panelhaving upper and lower elliptical portions connected by an narrowingincurvate intermediate portion, said upper elliptical portions having aleading edge each of said panels attached peripherally one to the otherin matched contour; ii) a first elastic strip attached to said inner andouter panels along each side of said intermediate portion; iii) a firstplurality of snap members attached to each end of both the inner andouter upper elliptical body portions; iv) a second plurality of snapmembers attached to said lower body portion of said outer panelcooperatively fastenable with said first plurality snap members in amanner whereby said female snap members are arranged in pairs located atacute angles either side of a longitudinal center line running throughsaid upper and lower body portions; and v) a removable, reusable,absorbent pad inserted between said inner and outer panels and locatedalong said intermediate portion and extending into said upper and lowerbody portions; and b) folding said diaper in a manner delimiting a shapehaving front and rear waist portions, an intermediate crotch portion, apair of leg openings defined by marginal edges of said crotch portion,and front and rear portions separated from one another by said crotchportion; and c) connecting said male snap members to said female snapmembers.
 13. The method according to claim 12 further comprising thestep of adding an elastic strip along said leading edge of said upperpanel to allow for waist line expansion when said snaps are secured. 14.The method according to claim 12 further comprising the step ofselectively securing each said first male snap members to any one of aplurality of said female snap members for adjusting said waist sizewithout affecting leg opening size.
 15. The method according to claim 12further comprising the step of selectively securing each said secondmale snap members to any one of a plurality of said female snap membersfor adjusting said leg opening size without affecting waist openingsize.
 16. The method according to claim 12 firther comprising the stepof removing said absorbent pad without removing the diaper from a wearerof said diaper.